Consideration of the recyclability of recycled plastic in the context of additive manufacturing in the field of dental technology for the production of dental models

The aim of the RecycAligner research project is to explore whether and how frequently additively manufactured denture models that are used to manufacture aligners can be recycled. Extrusion-based additive manufacturing (fused filament fabrication, FFF) is being investigated.

The questions of degradation, toxicology and surface quality of additively manufactured denture models have not yet been sufficiently answered. The FFF process on a filament or granulate basis enables direct recyclability without chemical treatment.

The investigated process is compared with other model-based processes (SLA process) and model-free processes (direct printing of aligners) in terms of toxicology and clinical suitability. The focus is on material properties and the fit between aligners and reference models, as these affect therapeutic force development. The toxicological investigations evaluate the presence of mutagenic, teratogenic, genotoxic, cytotoxic, and estrogen-active substances in the intermediate and final products of the processes.

A circular economy in the dental field can make the growing market for dental correction more sustainable and reduce waste production through resin-based methods.

The experts in additive manufacturing at IPH are working closely with the orthodontics department at LMU Klinikum München on the RecycAligner research project.